Hydrogen tanks set to reshape zero emission aviation sector

by Robert Schreiber
Berlin, Germany (SPX) Nov 26, 2025

A new scientific review highlights the urgent challenge of reducing aviation's carbon footprint, as air transport contributes 3 to 4 percent of global CO2 emissions. Hydrogen is identified as a fuel capable of eliminating in-flight emissions if onboard storage obstacles are overcome. Researchers examine technical developments in hydrogen tanks, focusing on their ability to store either gaseous or liquid hydrogen under extreme conditions while integrating with aircraft construction.

For gaseous hydrogen, advances in composite materials allow tanks to withstand pressures reaching thousands of psi. Liquid hydrogen storage relies on maintaining cryogenic temperatures near minus 253 degrees Celsius, using highly effective insulation to minimize heat loss. Tanks constructed from carbon fiber-reinforced polymers are emphasized for their strength-to-weight qualities, essential for aviation because hydrogen tanks often require more volume than conventional kerosene tanks.

Efficiency data from the EU's Cryoplane project indicate liquid hydrogen tanks currently support hydrogen production efficiencies between 70 and 85 percent for steam reforming methods, with renewable electrolysis showing potential above 60 percent. Researchers note the implications of green hydrogen adoption: it would reduce global aviation emissions, potentially by 100 percent, while lowering operational costs once hydrogen becomes price-competitive with kerosene, anticipated by 2040. Structural health monitoring systems incorporated in hydrogen tanks could reduce maintenance costs and improve safety and reliability for the industry's workforce, which supports over 65 million jobs.

Testing of early hydrogen-powered aircraft, such as the Soviet TU-155, has demonstrated technical feasibility. Retrofitting existing aircraft with insulated composite tanks is considered a practical strategy for accelerating hydrogen adoption, while innovative aircraft designs using blended wings might optimize liquid hydrogen storage and flight range.

Areas for further study include developing composites resistant to hydrogen embrittlement and improving insulation methods to limit energy losses. Airport infrastructure must evolve, with potential onsite green hydrogen production powered by solar or wind and reserves matching current kerosene storage needs. Hybrid hydrogen systems - combining hydrogen with biofuels or batteries - may become more common to reduce NOx emissions through improved combustion processes.

Commercial hydrogen-powered aircraft may emerge by 2030 as manufacturers refine tank production and reduce weight. The successful integration of hydrogen tanks has potential to fully decarbonize aviation and influence transport sectors such as shipping and automotive. The report concludes that advanced hydrogen tanks are fundamental to zero emission aviation and calls for continued scientific collaboration.

Research Report:A survey on hydrogen tanks for sustainable aviation